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An Introduction to AlarmInsight
Agenda
• Alarm Management Overview– Definition– Scope of the Problem– Causes of the Problem– Consequences of the Problem
• Alarm Management Lifecycle• Alarm Management Solutions for ABB’s System 800xA
– ProcessGuard– Alarm MOCCA– AlarmInsight
• Putting the Pieces Together
Alarm Management Overview
Matrikon’s Alarm Management Definition
Process by which alarms are engineered, monitored, and managed to ensure safe, reliable operations
The Scope of the Problem• Operators typically monitor more than
5,000 devices• Each device typically has 4 to 5
alarms configured on it• Devices x alarms results in Operators
having to manage 20,000 to 25,000 alarms
• The average Operator gets 1,200 alarms per day, approximately 1 per minute!
• Engineering Equipment & Materials Users’ Association (EEMUA) recommends no more than 6 alarms per hour
The Causes of the Problem
• Historically, alarms were expensive and difficult to add resulting in careful review before implementation– Each had to be hardwired– Limited space in control panels
• Today, hardware and software advances has made it possible to alarm most devices at minimal cost– Large increase in the quantity of alarms– Less review resulting in reduced quality
The Causes of the Problem
• Alarms are continuously added– Often after incident reviews
• Changes in process– After de-bottlenecking projects
• Equipment changes and degrades– Different vendors with different
normal operating conditions– Wear resulting in reduced efficiency
• Seasonal changes to process
Common Problem Alarms Types
• Standing– No dynamic process logic
• Frequent– Poor TP value/s– Possible control problem
• Redundant• Improperly Prioritized
– EEMUA recommends process alarm priorities of:• 80% low• 15% medium• 5% high
Consequences of the Problem
• There are many negative consequences of poor alarm systems, some common ones include:
– Avoidable incidences– Regulatory fines– Off-spec product– Reduced safety– Reduced process optimization– Reduced plant reliability– High Operator stress
Alarm Management Lifecycle
Maintenance
ContinuousImprovement
Benchmarking & Assessment
Alarm Management Lifecycle
AlarmPhilosophy
AlarmRationalization
Implementation& Execution
• Alarm management is a process, not a product
• Matrikon recommends that the alarm management process be divided into six major areas
Alarm Management Lifecycle
AlarmPhilosophy
AlarmRationalization
Implementation& Execution
Benchmarking &Assessment • Analyze your system and
understand your problems
• Determine key performance metrics– Operator workload– Problem alarms– Compare facility performance
• Gap analysis (you cannot improve what you cannot measure)
Maintenance
ContinuousImprovement
AlarmPhilosophy
Alarm Management Lifecycle
AlarmRationalization
Implementation& Execution
Benchmarking &Assessment • Corporate document that
specifies
– Objectives of alarms
– Assign roles & responsibilities
– Procedures for defining alarms
– How to assign priorities
– Expected Operator responses
– Management of change
Maintenance
ContinuousImprovement
AlarmPhilosophy
AlarmRationalization
Alarm Management Lifecycle
Implementation& Execution
Benchmarking &Assessment • Systematic review and
documentation of each configured/engineered alarmable tag in the DCS
• Store information in Alarm Database
• Objective is to optimize alarm quantity and quality– Ongoing process, target 50 to 100
worst alarmable tag per day
Maintenance
ContinuousImprovement
AlarmPhilosophy
AlarmRationalization
Implementation& Execution
Alarm Management Lifecycle
Benchmarking &Assessment
• Implement alarm strategy on DCS• Implement advanced alarming strategies
– Alarm shelving• Temporary disabling of alarms depending on
process state
– Dynamic alarming• Change alarm limits depending on process
state
– Alarm grouping• Use top level alarm to summarize multiple
ones (with drill-down capability)
– Alarm eclipsing• Disable an H alarm if the HH alarm limit is
reached
Maintenance
ContinuousImprovement
Maintenance
AlarmPhilosophy
AlarmRationalization
Implementation& Execution
Alarm Management Lifecycle
Benchmarking &Assessment • Integrate into work practices and
embed into company culture
• Prevent unauthorized changes
• Track changes made
• Monitor performance
ContinuousImprovement
ContinuousImprovement
Maintenance
AlarmPhilosophy
AlarmRationalization
Implementation& Execution
Alarm Management Lifecycle
Benchmarking &Assessment • Analyze alarm floods during
upsets
• Frequent intervention analysis
– Identify opportunities for additional process automation (supervisory control)
Alarm Management Solutions for System 800xA
ProcessGuard
• Measures and analyzes alarms that have occurred• Referred to as “real-time” or “dynamic” alarms
• Alarm & event historian
• Automated alarm assessment
• Problem analysis reports
• Web visualization
• Universal connectivity
ProcessGuard• Problem analysis reporting
examples:
• Alarm count by console
• Alarm count by tag
• Operator
• Interventions
• Response times
• Chattering alarms
• Priority distribution
• Standing alarms
• Integrated alarm & process data
Alarm MOCCA
• Measures and analyzes alarms configured on DCS• Referred to as “configured” or “static” alarms
• Instant integrity assessment
• Automatic audit trail & MOC
• Master alarm database
• Easy alarm rationalization
• Assist & knowledge capture
AlarmInsight
• AlarmInsight seamlessly integrates ProcessGuard and Alarm MOCCA reports into the System 800xA environment
• Provides context sensitive alarm information for all alarms configured on System 800xA
L
L
AlarmInsight
• Reduces time to decision and action– Reduced nuisance alarms ensure
operator focus on valid and important alarms
• Maximizes engineering performance– Unified interface for control and alarm
management reduces engineering time associated with analysis
• Optimizes plant asset availability and performance – Proactive identification of equipment
problems through statistical analysis reduces downtime
AlarmInsight
• Integrates information for improved visibility– Alarm analysis reveals root causes and
areas for improvement
• Improves batch consistency and quality– Alarm and event analysis can uncover
performance problems that affect batch quality
• Reduces risk through high integrity– Increasing alarm integrity raises the
overall reliability of a control system and results in fewer incidents and increased productivity
Putting the Pieces Together
Alarm Management Workshops
Matrikon hosts regular and global hands-on alarm management workshops. Some of the practical skills attendees learn include:
• How to successfully eliminate up to 75% of their alarms
• How to improve safety standards, meet production demands and reduce trips
• How to employ proven procedures and strategies to prioritize and configure alarm settings
• How to build a successful alarm philosophy tailored specifically to their plant
Alarm Management Services
Matrikon offers globally based services to ensure that our clients get the most value from our products; these include:
• Standard and customized ProcessGuard product training courses
• Development of assessments, alarm philosophies, and business cases
• Alarm Rationalization for existing systems and systems under design
• Implementation of Management of Change solutions for control systems
• Advanced dynamic alarming solutions
Maintenance
ContinuousImprovement
AlarmPhilosophy
AlarmRationalization
Implementation& Execution
Benchmarking &Assessment
Applying Alarm Management Solutions
Alarm MOCCA
AlarmInsight, ProcessGuard& Alarm MOCCA
MatrikonServices
Group
&
AlarmManagement
Workshops
AlarmInsight & ProcessGuard